Mattress and its manufacture



May 15, 1934.

, 1930 2 SheetsfSheet 1 c. LOFMAN MATTRESS AND ITS MANUFACTURE FiledDec.

"l QSv Il 1930 2 Sheets-Sheet 2 C. LOFMAN MATTRESS AND ITS MANUFACTUREFiled Dec.

May 15, 1934.

Patented May 15, 19.34

^ A.UNiTED STATES 1,959,082 iim'rrmiss AND Irs MANUFACTURE `CharlesLofman, Riverside, Ill., assignor to S'. Karpen & Bros., Chicago, lll.,a corporation of West Virginia Application December 15, 1930, Serial No.502,533 l 7 Claims. l (Cl. 5-360) This invention relates particularly tomattresses or the like, in which the filling within the mattress-casingcomprises a body of springs suitably' connected together to afford 4aninner spring- 5 structure, and suitable loose lling material, such ashair, cotton or the like, which supplements the -spring-structure andcompletes the filling of the mattress.

'Ihe primary object isto provide an improved lo method of manufacture,which enables a superior product to be produced at a very moderate cost.A further object is the production of such improved product.

In accordance with the present invention, a suitable spring-structure,comprising ,a body of light upholstery springs suitably connectedtogether, is provided; a pre-built border-boxing (preferably quilted andcomprising inner and outer fabrics and interposed filling material) andmarginal inner edge-rolls are then Ltied 'or' stitched to the marginalportion of the springstructure at the planes of the upper and lowersurfaces thereof; loose, or felted filling or stumng material is thenplaced over the sides of the spring-structure and may be reected overthe inner edge-rolls; and the upper and lower casingfabrics are thenplaced in position and sewedto the upper and lower marginal portions ofthe border-boxing, it being understood that these portions project aboveand below, respectively, the upper and lowersurfaces of thespring-structure. vThemethod thus stated renders it possible to providethe mattress, or cushion, with edge-rolls in an extremely simpleandeffective manner. That is, one canin this manner producea haliroll edgewhich gives an exceedingly pleasing appearance and' effect, coupled withthe highest utility.

The invention is illustrated in preferred em- '40 bodiments in theaccompanying drawings, in

Which- Fig. 1 is a broken elevational view of one form cf quiltedborder-boxing; Fig. 2, a similar View of a slightlymodified form ofborder-boxing; Fig. 3, a vertical sectional view taken as indicatedatline 3 of Fig. 1; Fig. 4, a broken horizontal sectional View taken asindicated at line 4 of Fig. 1; Fig. 5, abroken elevational view of theimproved mat.. tress employingthe border-boxing illustrated in Fig. 1;Fig. 6, a broken vertical sectional View of the mattress shown in Fig.5; Fig. 7, Aa broken detailed sectional View showing a slightmodification in the attachment oithe` inner edge-roll to thespring-structure and boxing; Fig. 8, a broken plan view of a modifiedform of mattress, in which the inner edge-roll is positioned somewhatdifferently than in the preceding structures; Fig. 9,

Ia broken vertical sectional view of the structure shown in Fig. 8,the'upper layer of filling and the upper casing-fabric being omitted;'Fig. 10, a broken elevational view of the mattress shown in 60, Fig. 8,it being noted that the border-boxing of -Fig. 2 is vhere employed; andFig. 11, a brokenI elevational view showing the mattress constructedwith still another modification of the borderboxing.

Inthe construction illustrated in Figs. I and 3J?, the mattresscomprises a border-boxing A; a spring-structure B; inner edge-rolls C;ties 4or stitches D which unite the edge-rolls and the boxing to thespring-structure; layers of lling material E, which are placed over(above and below) the spring-structure after the border-boxing andedge-rolls have been secured to the marginal rows of springs of saidstructure; and horizontal casing-fabrics F constituting the upper andlower sheets of the casing.

The border-boxing A preferably is quilted in any suitable manner.Preferably, the boxing comprises an outer strip of casing fabric 1, aninner strip of muslin ,2, and an interposed layer 3 80 of filling, suchas cotton.

In the illustration given in Figs. I and 3 6-, the quilting is effectedby sewing the fabrics and interposed filling material together along thelongitudinal lines 4at a distance of an inch more 85 or less from theedges, and also sewing the parts together by oval lines of stitching inthe vertical plane, as indicated at 5, the ends or apices of the ovalsmeeting the longitudinal lines of stitches at the points 6.-

The spring-structure B may be formed in any suitable manner. Preferably,a body of light upholstery springs are set together in longitudinal andtransverse rows and are suitably connected together. In the illustrationgiven, a body of springs of the Marshall type is shown. In this type ofspring-structure, the upholstery springs 7 are inclosed in fabricpockets, or fabric cells 8, and the springs are united Vtogether byties, or

strings 9.

In forming a mattress in accordance with the present' invention, aworkman takes a body of springs and stitches to one marginal portion ofthe spring-structure the boxingV A and an edgeroll C. The stitching iscontinud above the body of springs until the border has been secured tothe spring-structure throughout the periphery thereof. The operation isrepeated at the other corner of the spring-structure. In theillustration given, the ties D may be understood as stitchcompleted, thestructure comprises the springstructure, the edge-rolls, and theborder-boxing properly united together.

In the illustration given, a layer of cotton or the like 10 is placedadjacent the marginal row of springs before the border-boxing isapplied.

'I 'he ties or stitchings D preferably extend wholly through the boxingand at the points where the stitching is exposed, the loops registerwith the apices of the ovals 5. That is, they register with the points6, where the apices of the ovals register with the horizontal lines ofstitchings 4.

After the boxing and edge-rolls have been applied to thespring-structure, the workman places the layer of lling material E uponthe springstructure, places a fabric F thereover, and then, by means ofa sewing machine, sews the edgeportion of the fabric F to the upper edgeportion of the fabric 1 of the boxing, as indicated at 11. In formingthe seam at 11, a binding tape 12 is preferably folded over the edges ofthe fabric and sewed into the seam.

Having-completed the mattress at one side, the

structure is reversed, the filling E is applied over thespring-structure, the other horizontal casingfabric F is applied and thefabrics are united at the corner seam 11.

'By reference to Fig. 3, it will now be understood that the effect ofthe method described is to produce at the border-boxing inwardly drawnlines 4 which extend completely about the mattress periphery, asindicated in Fig. 5. However, the upper and lower surfaces of themattress are not drawn downwardly or inwardly near the edges, so thatthe result is to leave the upper and lower casing-fabrics substantiallysmooth near the margins, and simply rounded over to meet the seam 11, asindicated at 14. Thus, something approaching a pin-cushion effect andinvolving a half edge-roll effect is produced. The result isanexceedingly pleasing appearance, coupled with a luxurious edge effectfor the mattress.

In Fig. 7, a method of applying the inner edgeroll C is shown in somedetail. A thick strip of cotton, or a thick strip of curled hair (havingcheese-cloth secured to it, if desired) is employed. This strip may beconnected with the boxing and with the spring-structure by means of theties D, as shown in Fig. 7. That is, the stitchings may pass through thecentral portion of the strip. and the strip may ultimately be lled, soas to form a row when the casing-fabrics are to be united at the cornerseam of the mattress. It will be understood that the illustrations aremore or less schematic, it being diilicult to reproduce the exact`structure after it has been completed. Moreover, the details may bevaried.

In the modification shown in Figs. 2 and 8-10, the structure is similarto that already described, and parts are correspondingly designated,except vthat the modified border-boxing is designated A( and themodified edge-roll is designated C. In this construction, the quiltinglof the border-boxing is similar to that already described, except thatthe oval ends of the vertical figures designated 52 are formed byvertical lines of stitching As illustrated in Figs. 8 and 9, theedge-rol C' comprises a roll of hair 15 attached to or inclosed in astrip of cheese-cloth 152. In this example, a portion of the roll isinterposed between the spring-structure B and the border-boxing A. Theparts are united by ties or stitchings D', as appears in Figs. 9 and 10.

In the modification shown in Fig. 11, the structure is substantiallylike the previously described constructions, and corresponding parts arecorrespondingly lettered. In this instance, the border-boxing isdesignated A2, being slightly modified. y

The edge-roll is designated C2. The boxing A2 is quilted by means ofhorizontal lines of stitching 4a and vertical lines of stitching 4b,thus producing rectangular vertical figures between the planes of thehorizontal lines of stitching 4. The vertical lines of stitching producerudimentary vertical flutings between the lines of horizontal stitching.

The roll C2 is shown as comprising a hair roll. The filling materialabove the spring-structure, designated E2, is shown as comprising innerand outer layers of cotton or kapok 16 and an intermediate layer ofcurled hair 17. An exceedingly luxurious effect and an extremelypleasing appearance is secured in this construction. The ties orstitches D2 connect the boxing A2 with the edge-roll C2 and with thespring-structure in the manner described with reference tothe previouslydescribed constructions.

In this instance, the short exposed loops of the ties D2 register withthe intersections of the vertical lines of stitching 4b with thehorizontal lines of stitchings 42.

From the description given, it will be understood that the improvedmethod obviates the necessity of carrying the ties or stitches whichform the edge-roll of the mattress through the layers of fillingmaterial above the springs and through the horizontal casing-fabric. Theeffect is to simplify the manufacture and improve the appearance.

The foregoing detailed description has been given for clearness ofunderstanding only and no unnecessary limitations should be understoodtherefrom, but the appended claims should be construed as broadly aspermissible in view of the prior art.

What I regard as new, and desire to secure by marginal rows of lightgauge upholstery springs;

stitching an internal edge-roll and a quilted boxing to the marginalrows by a common stitching at the plane of one surface of thespring-structure, said stitching being adapted to give a halfroll edgeeffect at the boxing and the edge-portion of said boxing projecting adistance above said surface of the spring-structure; applying a layer offilling material over the spring-structure; and applying a casing-fabricover said layer and sewing its edge-portions to the correspondingedgeportion of the boxing.

2. 'I'he method of mattress manufacture specined in claim 1 .as carriedout by introducing a portion of the edge-roll between the boxing and themarginal row of springs and simultaneously stitching the boxing and theedge-roll to the springs. 1

3. A method of manufacturing a mattress with roll-edge effect whichcomprises: forming a quilted border-boxing having horizontal lines ofstitching some distance from its edges and having vertical stitchedgures intersecting at their ends the horizontal lines of stitchings;stitching by a common stitching the pre-formed borderboxing andanedge-roll to the marginal rows of a body of coil springs serving as amattress therein, said stitchings passing wholly through theborder-boxing and registeringrat their exposed loops with the points ofintersection between the vertical stitchings and the horizontalstitchings of the border-boxing; applying a layer of filling materialover the springs; and applying a casing-fabric over said layer ofmaterial and sewing the edge-portions thereof to the edge-portions ofthe boxing.

4. In a mattress structure: a body of coiled springs adapted to serve asa mattress lling; a quilted, pre-built border-boxing adjacent themarginal rows of springs; internal edge-rolls atthe junctions betweenthe border-boxing and the marginal rows of springs; and common tiesconnecting the border-boxing and the border rows of springs to theinternal edge-rol1s, said ties adapted to give a half-edge roll effectto the border-boxing.

5. A structure as speciiied in claim 4, in combination with layers oflling material above and 3 below the body of springs and casing-fabricsover said layers and having their edge-portions sewed to the edges ofthe border-boxing, said casing Afabrics presenting smooth unbrokensurfaces with '7. A method of manufacturing a mattress withhalf-roll-edge effect, which comprises: employing as a filling aspring-structure having marginal rows of light gauge upholstery springs;introducing an edge-roll having a portion thereof between the boxing andthe marginal row of springs; simultaneously stitching said edge-roll andthe boxing to the springs applying a layer of lling material over thespring-structure; and

applying a casing-fabric over said layer and sewing its edge-portions tothe corresponding edge portion of the boxing.

CHARLES LOFMAN.

